Extruded protein product and methods of making

ABSTRACT

The present disclosure relates to extruded protein products and methods for producing an extruded protein product. In particular, an extruded piece is disclosed having a high protein content and having a desirable texture and flavor. Methods for making an extruded piece include processing, under extrusion conditions, a combination of a powdered protein ingredient, a protein matrix disruptive ingredient, water, and an oil.

TECHNOLOGY

The present disclosure generally relates to an extruded protein productand methods of making such a product.

BACKGROUND

High protein food products have found popularity among consumers as away to eat nutritionally dense foods. Consumers want diverse ways to getincreased protein into their diets. Thus, there is a need for new highprotein food products to satisfy the increasing consumer desire forprotein.

SUMMARY

Provided herein is a composition including extruded pieces. The extrudedpieces include protein in an amount of about 30% to about 90% by weight,a protein matrix disruptive ingredient in an amount of from about 5% toabout 50% by weight, oil in an amount of from about 2% to about 20% byweight, water in an amount of from about 1.5% to about 8% by weight, andinclusions in an amount of from 0% to about 50% by weight.

The extruded pieces can have a substantially non-linearly orientedprotein matrix.

In some embodiments, the extruded pieces can have a texture analysismeasurement of from about 1000 g to about 7400 g force and/or a densityof from about 0.5 g/cc to about 1.0 g/cc.

The extruded pieces can have a rough and/or uneven surface.

The protein can include one or a combination of soy protein, wheyprotein, bean protein, pea protein, wheat protein, canola protein, oralgae protein.

In some embodiments, the protein matrix disruptive ingredient can be aflour or a syrup. In some embodiments, the protein matrix disruptiveingredient can include a starch, a sugar, or a fiber.

In some embodiments, the inclusions can be one or a combination of nuts,seeds, fruit, grains, or coconut. In some embodiments, the extrudedpieces can have inclusions substantially uniformly distributedthroughout the extruded pieces.

The oil can be substantially uniformly distributed throughout theextruded pieces.

In some embodiments, the extruded pieces can have a sugar-based coating,a fat-based coating, or a protein-based coating.

In some embodiments, an extruded piece can be adhered with one or moreedible component to form a cluster. In some embodiments, an extrudedpiece can be adhered to one or more additional extruded piece to form acluster.

A food product is also provided herein. A food product includes foodproduct pieces and extruded pieces having protein in an amount of about30% to about 90% by weight, a protein matrix disruptive ingredient in anamount of from about 5% to about 50% by weight, oil in an amount of fromabout 2% to about 20% by weight, water in an amount of from about 1.5%to about 8% by weight, and inclusions in an amount of from 0% to about50% by weight.

A composition is provided herein including particulates derived fromextruded pieces, where the extruded have protein in an amount of about30% to about 90% by weight, a protein matrix disruptive ingredient in anamount of from about 5% to about 50% by weight, oil in an amount of fromabout 2% to about 20% by weight, water in an amount of from about 1.5%to about 8% by weight, and inclusions in an amount of from 0% to about50% by weight. The particulates can be coated on a food product orformed into a food product.

A food product or kit is provided herein. The food product or kitincludes a first food component and a second food component, where thefirst food component includes extruded pieces having protein in anamount of about 30% to about 90% by weight, a protein matrix disruptiveingredient in an amount of from about 5% to about 50% by weight, oil inan amount of from about 2% to about 20% by weight, water in an amount offrom about 1.5% to about 8% by weight, and inclusions in an amount offrom 0% to about 50% by weight.

A method of making a food product is also provided herein. The methodincludes processing, under extrusion conditions, a powdered proteiningredient comprising at least 45% protein by weight of the powderedprotein ingredient and a protein matrix disruptive ingredient combinedwith water and an oil to form a protein matrix composition having aprotein content of from about 10% to about 65% by weight, a moisturecontent of from about 25% to about 55% by weight and an oil content offrom about 1% to about 15% by weight, and forming the protein matrixcomposition into pieces to form the food product.

The extrusion conditions can include a specific mechanical energy (SME)of from about 8 Wh/kg to about 100 Wh/kg, a die pressure of from about150 PSI to about 1000 PSI, and/or a die temperature of from about 200°F. to about 350° F.

In some embodiments, the powdered protein ingredient includes at least aportion of the protein matrix disruptive ingredient.

In some embodiments, the protein matrix disruptive ingredient can be aflour or a syrup. In some embodiments, the protein matrix disruptiveingredient can include a starch, a sugar, or a fiber.

In some embodiments, the pieces can have a substantially non-linearlyoriented protein matrix.

The method can further include drying the protein matrix compositionpieces to a moisture content of from about 1.5% to about 8% by weight toform extruded pieces.

In some embodiments, extruded pieces have a texture analysis measurementof from about 1000 g to about 7400 g force, and/or a density of fromabout 0.5 g/cc to about 1.0 g/cc. In some embodiments, the oil issubstantially uniformly distributed throughout the pieces.

In some embodiments, the method can further include applying asugar-based or protein-based coating to the extruded pieces to formcoated pieces and drying the coated pieces.

In some embodiments, the method can further include applying a fat-basedcoating to the extruded pieces to form coated pieces and cooling thecoated pieces.

In some embodiments, the method can further include comminuting theextruded pieces to form particulates. The method can further includeproducing a food product including the particulates and/or coating afood product with the particulates.

In some embodiments, the method can further include processinginclusions with the powdered protein ingredient, protein matrixdisruptive ingredient, water, and oil. The inclusions can include one ora combination of nuts, seeds, fruit, grains, or coconut.

These and various other features and advantages will be apparent from areading of the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 includes macroscopic images of the surfaces of an extruded pieceaccording to one embodiment (FIG. 1A), a piece that does not include oil(FIG. 1B), two commercially available textured vegetable proteinproducts (FIGS. 1C and 1D), and two commercially available puffed soyprotein crisps (FIGS. 1E and 1F).

FIG. 2 includes macroscopic images of cross sections of an extrudedpiece according to one embodiment (FIG. 2A), a piece that does notinclude oil (FIG. 2B), two commercially available textured vegetableprotein products (FIGS. 2C and 2D), and two commercially availablepuffed soy protein crisps (FIGS. 2E and 2F).

FIG. 3 includes light micrographs of an extruded piece according to oneembodiment (FIG. 3A), a piece that does not include oil (FIG. 3B), twocommercially available textured vegetable protein products (FIGS. 3C and3D), and two commercially available puffed soy protein crisps (FIGS. 3Eand 3F).

FIG. 4 includes confocal micrographs of an extruded piece according toone embodiment (FIG. 4A), a piece that does not include oil (FIG. 4B),two commercially available textured vegetable protein products (FIGS. 4Cand 4D), and two commercially available puffed soy protein crisps (FIGS.4E and 4F).

FIG. 5 is a polarized light micrograph of an extruded piece havinginclusions according to another embodiment.

DETAILED DESCRIPTION

Extrusion technology has begun to produce protein products that have anenjoyable texture, while reducing or eliminating the use of animalprotein. Many of these products are designed to mimic whole or groundmeat and are meant to be eaten in place of meat. However, consumersexpect an even greater variety of high protein foods that are suitablefor different eating occasions. As described herein, a new proteinproduct has been produced having a high protein content and having anenjoyable texture and flavor that is suitable for a wide variety ofeating occasions.

A protein product provided herein can be a composition comprisingextruded pieces. Extruded pieces described herein comprise protein, aprotein matrix disruptive ingredient, oil, and water. In someembodiments, extruded pieces provided herein include inclusions.

Extruded pieces provided herein comprise protein in an amount of about30% to about 90% (e.g., about 50% to about 75%) by weight protein. Theamount and type of protein included in extruded pieces described hereincan be selected to produce a protein matrix when extruded in thepresence of water and an oil.

As illustrated in FIGS. 3A and 4A, an extruded piece provided herein canhave a protein matrix that is substantially non-linearly oriented. Thisis in contrast to an extruded product having a substantially linearlyoriented protein matrix, such as an extruded piece that does not containoil, as illustrated in FIGS. 3B and 4B, or a known textured vegetableprotein product, as illustrated in FIGS. 3C, 3D, 4C, and 4D. Withoutbeing bound to theory, it is believed that a substantially non-linearlyoriented protein matrix can contribute to a desired texture of anextruded piece provided herein.

Protein suitable for use in an extruded piece includes plant-basedprotein (e.g., soy protein, pea protein, wheat protein, oat protein,bean protein, canola protein, lentil protein, and the like),microbe-based protein (e.g., algae protein, bacterial protein, and thelike), fungal protein (e.g., yeast protein, mushroom protein, and thelike), and animal-based protein (e.g., dairy protein, egg protein,insect protein, and the like). In some embodiments, a protein can beselected to produce a desired characteristic. For example, soy, pea, orbean protein, or the like, can be selected to exclude grain-basedingredients, or whey protein can be selected to produce extruded pieceshaving a crunchier texture. Other characteristics can include, forexample, GMO-free, gluten-free, soy-free, and/or allergen free. In someembodiments, blends of proteins can be used in extruded pieces providedherein.

Extruded pieces also comprise a protein matrix disruptive ingredient inan amount of from about 5% to about 50% (e.g., about 15% to about 40%)by weight. As used herein, the term “protein matrix disruptiveingredient” refers to one or a combination of a flour (e.g., a grainflour, a legume flour, a vegetable or fruit powder, cocoa, or the like),a starch (e.g., tapioca starch, corn starch, a modified starch, apregelatinized starch, or the like), a sugar (e.g., sucrose, fructose,lactose, or the like), a fiber (e.g., sugar cane fiber, inulin, oatfiber, pea fiber, bran, hull fiber, or the like), a polyol (e.g.,glycerol or the like), syrups (e.g., corn syrup, tapioca syrup, honey,or the like), or the like. Without being bound by theory, it is believedthat a protein matrix disruptive ingredient disrupts the protein matrixin an extruded piece provided herein to contribute to a desired textureand/or protein matrix structure of the extruded piece.

A protein matrix disruptive ingredient can be selected, for example, inorder to provide a desired nutritional profile, flavor, sweetness,and/or texture to an extruded piece that contains the protein matrixdisruptive ingredient. For example, oat hull fiber can be selected toproduce extruded pieces having a desired fiber content, or a syrup canbe selected to adjust texture and/or taste. In some embodiments, aprotein matrix disruptive ingredient can be selected to provide adesired characteristic for an extruded piece, such as being grain-free,gluten-free, GMO-free, soy-free, and the like. For example, tapiocaflour or starch can be selected to produce a grain-free extruded piece.

Extruded pieces provided herein include oil in an amount of from about2% to about 20% (e.g., about 2% to about 15%) by weight. Oil in anextruded piece provided herein can be distributed substantiallyuniformly throughout the piece. This is in contrast to known texturedvegetable protein products, which generally are made from defatted orlow fat ingredients and do not contain oil or only residual amounts ofoil (e.g., less than 2% by weight), or if oil is present, it is foundmainly near the surface as a surface treatment of the textured vegetableprotein. For example, oil spraying is commonly used to topically applyseasoning or flavor to textured vegetable protein products. Thedisclosed extruded pieces also contrast to puffed protein productscurrently available (e.g., soy crisps), which generally containsubstantially no oil in the matrix.

Any edible oil is suitable for use in an extruded piece provided herein.Preferably, an oil included in an extruded piece is liquid at roomtemperature. Suitable oils include, without limitation, canola oil,olive oil, soy oil, sunflower oil, corn oil, and the like. An oil to beincluded in an extruded piece can be selected based on, for example,nutritional profile, compatibility with extrusion process and/orequipment, texture and/or mouthfeel imparted to the extruded piece,and/or price.

Extruded pieces described herein include water in an amount of fromabout 1.5% to about 8% (e.g., about 1.5% to about 6%) by weight. Theamount of water in an extruded piece is generally selected in order toprovide shelf stability and/or a desired texture to the extruded piece.A lower water content can be selected to increase shelf life of anextruded piece. In some embodiments, a higher water content can beselected in order to reduce the hardness of an extruded piece. Watercontent can also be selected to maintain solubility of one or moreingredients, such as an antioxidant, in an extruded piece.

In some embodiments, extruded pieces provided herein include inclusionsup to about 50% by weight. As used herein, the term “inclusion” refersto a substantially solid edible particle. An inclusion is visually(i.e., macroscopically) distinguishable from the protein matrix of anextruded piece. Inclusions, when included in an extruded piece, aresubstantially uniformly distributed throughout the piece. Examples ofinclusions include, without limitation, nut pieces, whole grain pieces,seeds and/or seed pieces, fruit pieces, coconut, confection pieces, andthe like.

Additional ingredients can be included in extruded pieces providedherein. An additional ingredient can be selected to impart a desirednutritional profile, flavor, sweetness, texture, shelf life, and/orvisual appearance to an extruded piece, or to provide an advantage tothe production process of an extruded piece. Examples of additionalingredients that can be included in an extruded piece include, withoutlimitation, flavorants, nutritive and/or non-nutritive sweeteners,salts, colorants, antioxidants, vitamins, and/or minerals, and the like.

Extruded pieces provided herein can have a texture analysis measurementof from about 1000 g to about 7400 g (e.g., from about 1000 g to about5600 g) force. As used herein, the term “texture analysis measurement”refers to an average 50% strain force of 10 replicate measurements in gobtained from the following protocol: a single piece is placed on thestage of a TA.HDP/us Texture Analyzer (Texture Technologies,Massachusetts, USA) and subjected to a 50% strain test at a speed of 2mm/second using a 50 kg load cell and a 1 inch cylindrical stainlesssteel probe.

In some embodiments, extruded pieces can have a density of from about0.5 g/cc to about 1.0 g/cc (e.g., from about 0.7 g/cc to about 1.0 g/cc,or about 0.8 g/cc to about 0.9 g/cc). As used herein, density ismeasured by the displacement of granular sodium chloride. About 150 ccof sodium chloride is placed in a 250 ml graduated cylinder and tappedin a tap density analyzer 300×. The volume of salt is recorded to thenearest cc. The salt is then removed from the cylinder. The salt ispoured back into the cylinder in about 10-20 cc aliquots alternatingwith pieces of a known weight of extruded pieces until the volume isapproximately 150 cc. The remaining salt is then placed in the cylinder.The cylinder is again tapped 300× in the tap density analyzer. Thevolume is recorded and the particle density of each sample is calculatedas the weight of the sample divided by the difference in tapped volumewith and without sample present.

In some embodiments, extruded pieces provided herein can have a rough oruneven surface. A rough surface can provide a visually interestingappearance to extruded pieces. In some embodiments, inclusions cancontribute to a rough or uneven surface of an extruded piece.

In some embodiments, extruded pieces can have average diameter of fromabout 2 mm to about 15 mm (e.g., from about 5 mm to about 10 mm). Thesize of an extruded piece can be adjusted for the desired use of theextruded piece or to provide a manufacturing advantage. For example, thesize of an extruded piece can be adjusted to provide a desired size foreating as a stand-alone snack. In another example, the size of anextruded piece can be adjusted to result in a desired drying time duringmanufacturing. Piece size can be adjusted using known methods, such asdie size selection, rate of extrusion, and/or cutter speed.

Extruded pieces can be produced by processing, under extrusionconditions, a powdered protein ingredient and a protein matrixdisruptive ingredient with sufficient water and an oil to form a proteinmatrix composition. As used herein, the term “extrusion conditions”refers to subjecting components to heat, pressure, and shear in anextruder. Extrusion conditions can include applying sufficient specificmechanical energy (SME) (e.g., at least about 8 Wh/kg, or from about 10Wh/kg to about 100 Wh/kg, about 10 Wh/kg to about 50 Wh/kg, or fromabout 15 Wh/kg to about 35 Wh/kg) to produce extruded pieces having adesired protein matrix. In some embodiments, extrusion conditions cancomprise a die temperature of at least 200° F. (e.g., from about 200° F.to about 350° F., or from about 250° F. to about 300° F.). As usedherein, the term “die temperature” refers to the temperature of aprotein matrix composition inside the die of an extruder just beforeexiting the die. In some embodiments, extrusion conditions can comprisea die pressure of at least about 150 PSI (e.g., from about 150 PSI toabout 1000 PSI, about 200 PSI to about 600 PSI, or from about 250 PSI toabout 350 PSI). As used herein, the term “die pressure” refers to thepressure a protein matrix composition is exposed to inside the die of anextruder just before exiting the die.

A powdered protein ingredient, as used herein, is an edible dryingredient comprising at least 45% protein (e.g., at least 50%, at least70%, or at least 90%) by weight. Examples of powdered proteiningredients include, without limitation, flours having a protein contentof at least 45% (e.g., defatted soy flour), protein concentrates (e.g.,soy protein concentrate, pea protein concentrate, whey proteinconcentrate, and the like), protein isolates (e.g., soy protein isolate,pea protein isolate, whey protein isolate, and the like), pure proteins,and combinations thereof. A powdered protein ingredient can be includedin an amount sufficient to produce a protein matrix composition having aprotein content of about 10% to about 65% (e.g., about 15% to about 50%)protein by weight of the protein matrix composition.

In some embodiments, a powdered protein ingredient can comprise aprotein matrix disruptive ingredient. For example, a protein concentrateor a protein isolate can include, for example, starch, sugar, fiber,and/or inorganic components, and the like. In some embodiments, all orpart of the protein matrix disruptive ingredient can be combined withpowdered protein ingredient, water, and oil as a separate ingredient.

Water and oil are combined with the powdered protein ingredient, proteinmatrix disruptive ingredient, and optional inclusions and/or otheringredients in amounts sufficient to form a protein matrix compositionhaving a moisture content of from about 25% to about 55% by weight andan oil content of from about 1% to about 15% by weight. Water can beprovided in any appropriate form. For example, tap or filtered water,fruit or vegetable juice, or the like, can be used to provide thedesired moisture content. In some embodiments, water and oil can beprovided as an emulsion for combination with the powdered proteiningredient, protein matrix disruptive ingredient, and optionalinclusions and/or other ingredients.

It has been discovered that incorporating oil into a protein matrixcomposition results in extruded pieces that have a desirable texture anda substantially non-linear protein matrix, while the addition of toomuch oil (e.g., more than 15% by weight) results in incompleteincorporation of the oil. It has also been discovered that too littlewater addition (i.e., less than about 25% by weight) can result in oilbeing squeezed from the protein matrix composition, which alters thetexture of extruded pieces and/or interferes with the proper function ofextruder equipment. However, it has also been discovered that theaddition of too much water (i.e., more than 55% by weight) can result inextruded pieces that are harder than desired. It has further beendiscovered that incorporation of water and oil into a protein matrixcomposition allows for the incorporation of inclusions that are visuallydistinguishable from protein matrix rather than being crushed ordegenerated during extrusion at low water and/or low or no oilconditions such that inclusions remain visually indistinguishable.

The amounts of oil and/or water combined with a powdered proteiningredient and protein matrix disruptive ingredient can be adjusted inorder to result in a desired appearance and/or texture of extrudedpieces. As the amount of oil is increased, extruded pieces generallyappear rougher and have a crunchier texture. As the amount of water isincreased, extruded pieces generally appear smoother and have a hardertexture.

The amounts of oil and/or water combined with a powdered proteiningredient and protein matrix disruptive ingredient can also be adjustedin order to adjust the amount of shear a protein matrix composition issubjected to. Generally, higher amounts of water and/or oil reduce theamount of shear that a protein matrix composition is subjected to. Insome embodiments, higher water and/or oil can be used to make extrudedpieces with relatively large inclusions.

In some embodiments, dry ingredients, such as a powdered proteiningredient, a protein matrix disruptive ingredient, inclusions and/orother optional components, can be combined prior to combining with waterand/or oil under extrusion conditions. In some embodiments, componentscan be added stepwise or at essentially the same time before combiningunder extrusion conditions.

Extruders suitable for use in the methods provided herein can include,for example, a single screw, twin, or triple screw extruder, or a ringextruder. For example a co-rotating, intermeshing, twin screw extrudercan be used in a method provided herein. Manufacturers for co-rotatingtwin screw extruders include, for example, Coperion, Wenger, Clextral,Bersttorf, APV, Buhler, and Leistritz. Manufacturers for single screwextruders include, for example, Wenger, APV, and Buhler.

A protein matrix composition can be formed into pieces using anysuitable method to form protein matrix composition pieces. For example,a protein matrix composition can passed through an extrusion die andthen cut in order to form pieces.

Following formation, protein matrix composition pieces are dried to formextruded pieces using any appropriate method to reach a moisture contentof from about 1.5% to about 8% to form extrude pieces. For example,protein matrix composition pieces can be subjected to heated air inorder to dry them to the desired moisture content.

In some embodiments, extruded pieces provided herein can be packaged andsold as a food product without any other components. Such packagedextruded pieces can be intended to be eaten as a food product alone orin combination with other food products. For example, extruded piecescan be packaged and sold as a stand alone snack or can be used as atopping for yogurt or oatmeal. Extruded pieces provided herein have atexture suitable such that they need not be further prepared for eatingby, for example, heating or soaking However, it is to be understood thatan individual may enjoy heating and/or soaking extruded pieces providedherein during various eating occasions, such as when combined withoatmeal.

In some embodiments, extruded pieces provided herein can be combinedwith other food components to produce a food product. For example,extruded pieces can be combined with food product pieces, such as readyto eat (RTE) cereal pieces or popcorn, to produce a food product havingdesired protein content. In another example, extruded pieces can becombined with dried fruit and/or nuts to produce a snack mix typeproduct or a granola type product.

In some embodiments, extruded pieces provided herein can be packagedinto a kit with other food products. For example, extruded pieces can becombined as a kit with yogurt, which can be combined prior to eating.

In some embodiments, an extruded piece can be adhered with one or moreedible component, such as another extruded piece, nut pieces, fresh ordried fruit pieces, seeds, coconut, grain, and the like, to form acluster. An extruded piece and one or more edible component can beadhered to each other using any appropriate method and ingredients(e.g., edible binders and the like). For example, a cluster can beproduced using a combination of an extruded piece and rolled oatsadhered using a honey-based binder or slurry. Clusters can be providedas a food product alone or as part of a food product, such as a snackmix, ready to eat cereal, or oatmeal mix.

In some embodiments, extruded pieces provided herein can be comminutedinto particulates (i.e., having an average diameter of less than 2 mm)to produce a composition derived from extruded pieces that resemblescrumbs or a powder. Such particulates can be used, for example, to coatfood products, such as ready to eat cereal pieces, snack food pieces,and the like. In some embodiments, particulates derived from extrudedpieces provided herein can be combined with other components and formedinto a food product, such as ready to eat cereal pieces, snack foodpieces, baked goods, and the like. In some embodiments, particulatesderived from extruded pieces disclosed herein can be used in additionto, or to partially or completely replace, protein ingredients, such assoy protein concentrate, in other food products where a high proteincontent is desired.

It is to be understood that extruded pieces provided herein can be usedfor either sweet or savory applications. Extruded pieces disclosedherein can provide a benefit of being a high protein stand-alone foodproduct or provide added protein in combination with other components infood products while also providing an improved flavor and/or textureover other known high protein pieces, such as textured vegetable proteinor puffed protein crisps.

EXAMPLES Example 1

Formulations including soy protein isolate (SPI), flour (F), sugar (S),oil (O), water (W), and flavor (R) according to Table 1 (SPI, F, S, andR are shown as % weight of dry ingredients and O and W are shown as %weight of protein matrix composition) were combined in a Buhler BCTL-42extruder (Buhler Inc., Minnesota, USA) to form a protein matrixcomposition. The protein matrix composition was extruded through asingle hole die having a diameter of 1.59 mm and cut to form proteinmatrix composition pieces approximately 5 mm to 10 mm. The pieces weredried using tray dryer to a moisture content of about 1.5% to about 8%to form extruded pieces.

TABLE 1 Die SME Die temp. press. Sample SPI F S O W R (Wh/kg) (° F.)(PSI) 1 75 20 4 5.4 59.8 0.6 9.6 248 152 2 75 20 4 6.5 50.4 0.6 15.4 253199 3 75 20 4 7.8 40.4 0.6 24.6 265 297 4 75 20 4 9.0 30.7 0.6 27.9 274330 5 75 20 4 0 33.7 0.6 82.6 313 810 6 75 20 4 3.5 56.6 0.6 14.9 257193 7 75 20 4 4.4 46.7 0.6 17.1 262 273 8 75 20 4 5.2 36.6 0.6 24.5 275411 9 75 20 4 1.8 37.9 0.6 32.1 284 506 10 75 20 4 1.5 48.2 0.6 20.0 275320 11 75 20 4 1.2 58.0 0.6 14.5 259 213 12 65 30 4 6.5 50.1 0.6 12.6256 194 13 65 30 4 7.8 40.3 0.6 18.3 263 294 14 65 30 4 9.0 30.7 0.619.9 274 305 15 65 30 4 5.9 27.6 0.6 23.9 282 377 16 65 30 4 5.6 31.80.6 23.1 282 412 17 65 30 4 4.8 41.7 0.6 19.9 272 337 18 65 30 4 1.643.0 0.6 25.1 275 370 19 65 30 4 1.9 33.1 0.6 46.2 288 547 20 65 30 42.1 2 0.6 47.8 291 571

Formulations were attempted using 25% moisture or less, but oilseparated during extrusion.

Extruded pieces were eaten to determine acceptability of texture forconsumption without further preparation (Table 2). Extruded piecesproduced using a protein matrix composition having 55% moisture orgreater were identified as having an unacceptable hardness whenconsumed. In addition, extruded pieces produced using a protein matrixcomposition having 55% moisture or greater exhibited a smooth, evensurface. Extruded pieces produced using a protein matrix compositionhaving no added oil resembled TVP and were relatively hard.

The protein content in extruded pieces from each of the samples wasmeasured (as % weight) using the Dumas method. Overall fat content (as %weight) was measured by gas chromatography. Moisture content of extrudedpieces was also measured by subjecting the extruded pieces to a vacuumoven at 70° C. for 16 hours. Protein, fat, and moisture content areshown in Table 2.

TABLE 2 Measured Acceptable protein (% Measured fat Moisture (% texturefor Sample wt) (% wt) wt) consumption 1 58.5 13.2 6.7 No 2 61.4 13.9 2.3Yes 3 61.9 13.4 1.9 Yes 4 61.6 12.3 2.9 Yes 5 65.7 1.9 7.8 No (TVP-like)6 63.6 10.7 3.7 No 7 63.6 9.5 4.0 Yes 8 63.4 10.6 4.2 Yes 9 67.9 6.3 2.3Yes 10 67.4 4.9 2.9 Yes 11 67.4 5.0 3.8 No 12 55.7 14.6 2.1 Yes 13 54.713.1 4.0 Yes 14 53.8 12.1 4.0 Yes 15 56.3 9.0 4.6 Yes 16 56.7 9.4 3.8Yes 17 57.0 10.1 3.2 Yes 18 59.9 5.7 3.5 Yes 19 60.5 4.3 3.0 Yes 20 60.64.4 3.4 Yes

Texture analysis measurements were obtained for extruded pieces fromeach sample. Extruded pieces from each sample individually placed on thestage of a TA.HDPlus Texture Analyzer (Texture Technologies,Massachusetts, USA) and subjected to a 50% strain test at a speed of 2mm/second using a 50 kg load cell and a 1 inch cylindrical stainlesssteel probe The average 50% strain force of 10 replicates determinedthat acceptable extruded pieces identified in Table 1 had textureanalysis measurements from about 400 g to about 6600 g force, withtexture analysis measurements greater than about 1000 g force being morepreferred. Texture analysis measurements taken for a variety ofcommercially available textured vegetable protein (TVP) products, soldas meat analog, substitute, or imitation, ranged from about 7400 g toabout 9000 g force, while a variety of commercially available soy crispsranged from about 1300 g to about 1400 g force. Many available TVPproducts are considered to be too hard to be enjoyable to eat withoutsoaking in a liquid first.

Particle density measurements were obtained for extruded pieces fromeach sample. Extruded pieces from each sample were analyzed for densityby the displacement of granular sodium chloride. Briefly, about 150 ccof sodium chloride was placed in a 250 ml graduated cylinder and tappedin a tap density analyzer 300×. The volume of salt was recorded to thenearest cc. The salt was then removed from the cylinder. The salt waspoured back into the cylinder in about 10-20 cc aliquots alternatingwith pieces of a known weight of sample until the volume wasapproximately 150 cc. The remaining salt was then placed in thecylinder. The cylinder was again tapped 300× in the tap densityanalyzer. The volume was recorded and the particle density of eachsample was calculated as the weight of the sample divided by thedifference in tapped volume with and without sample present. The averageparticle density for acceptable extruded pieces (see, Table 1) rangedfrom about 0.7 g/cc to about 1.0 g/cc, with densities from about 0.8g/cc to about 0.9 g/cc being more preferred. Densities of a variety ofTVP products ranged from about 0.7 g/cc to about 0.8 g/cc, whilecommercially available soy crisps ranged from about 0.4 g/cc to about0.5 g/cc. Thus, while acceptable extruded pieces had a similar densityto commercially available TVP products, texture was somewhat reduced toresult in a product that provides a better eating experience than a TVPproduct without prior hydration.

Macroscopic and microscopic images of Sample 16 (Table 1), Sample 5,which contains no added oil (Table 1), two commercially available TVPproducts, and two commercially available protein (soy) crisps were takento examine the structure of each sample. The surface of extruded pieceswere imaged using an Epson ® V700 (Epson America Inc., California, USA)photographic scanner. Pieces were also sectioned using a razor blade andthe interior of pieces were also imaged using an Epson V700 photographicscanner. FIG. 1 shows macroscopic images of the surfaces ofrepresentative pieces of each sample, while FIG. 2 shows macroscopicimages of the interiors of representative pieces of each sample, with 1Aand 2A being Sample 16, 1B and 2B being Sample 5, 1C and 2C being afirst TVP product, 1D and 2D being a second TVP product, 1E and 2E beinga first protein crisp, and 1F and 2F being a second protein crisp.

Extruded pieces were prepared for transmitted light microscopy byhydrating pieces from each sample in a refrigerated 50:50 mixture ofTissue-Tek® O.C.T™ (Sakura Finetek Europe B.V., The Netherlands) andwater until the center was hydrated. Once rehydrated, pieces were frozenand then cut into 20 micron sections using a cryostatic microtome. Thesections were stained using 0.1% Ponceau 2R, which stains protein red,and an aqueous iodine solution, which stains starch blue. The sectionswere imaged using an Olympus® AX70 Microscope light microscope with a20× objective and Olympus® DP70 digital camera with a 10× eyepiece(Olympus America Inc., Pennsylvania, USA). FIG. 3 compares lightmicrographs of an example of an extruded piece (Sample 16 from Table 1;FIG. 3A), a piece containing no oil (Sample 5 from Table 1; FIG. 3B),two commercially available TVP products (FIGS. 3C and 3D), and twocommercially available soy crisps (FIGS. 3E and 3F). Sample 16 (FIG. 3A)had relatively large agglomerations of non-linearly oriented proteinsurrounded by protein matrix disruptive ingredient (starch in thisexample) in a loosely packed structure. This contrasts to Sample 5 (FIG.3B), which had linearly-oriented protein with protein matrix disruptiveingredient dispersed in spaces between protein strands. Commerciallyavailable TVP products (FIGS. 3C and 3D) appeared similar in structureto Sample 5, with linearly oriented protein. Without being bound totheory, it is believed that the similar, linearly oriented proteinstructure of the commercially available TVP products to Sample 5 is, inpart, due to absence of any significant amount of oil during extrusion.Commercially available soy crisps (FIGS. 3E and 3F) showedagglomerations of protein that are smaller and more tightly packedcompared to Sample 16 (FIG. 3A).

Extruded pieces were prepared for confocal microscopy bycross-sectioning representative pieces from each sample with a razorblade. Autofluorescence of at the cut surface was imaged using anOlympus Fluoview 1000 confocal microscope with a 4× objective and425-475 nm, 500-530 nm, and 560-660 nm emission filters after excitationat 405 nm, 488 nm, and 568 nm lasers, respectively. The images in FIG. 4are z-stacks of 10 micron optical sections, with imaged stacks from eachlaser overlaid. It was observed that the TVP samples autofluorescedunder the 568 nm laser, but the other samples did not. Thus, images forthe TVP samples (4C and 4D) include overlays of images obtained usingexcitation at 405 nm, 488 nm, and 568 nm, while images for Sample 16(4A), Sample 5 (4B), and commercially available protein crisps (4E and4F) include overlays of images obtained using excitation at 405 nm and488 nm.

Example 2

Extruded pieces including a protein matrix disruptive ingredientcomprising insoluble fiber (e.g., oat hull fiber), were produced.Formulations including soy protein isolate (SPI), flour (F), insolublefiber (IF), sugar (S), oil (O), water (W), and flavor (R) according toTable 3 (SPI, F, IF, S, and R are shown as % weight of dry ingredientsand O and W are shown as % weight of protein matrix composition) werecombined to form a protein matrix composition, formed, and driedsimilarly to Example 1.

TABLE 3 SME Die Die Sam- (Wh/ temp. press. ple SPI F IF S R W O kg) (°F.) (PSI) 1 55.4 20.0 20.0 4.0 0.6 43.0 4.7 29.8 274 300 2 55.4 20.020.0 4.0 0.6 40.9 8.9 23.0 270 242 3 55.4 20.0 20.0 4.0 0.6 48.9 7.816.1 261 194 4 45.4 20.0 30.0 4.0 0.6 48.6 7.8 17.3 256 201 5 45.4 20.030.0 4.0 0.6 36.4 9.7 31.4 271 291 6 45.4 20.0 30.0 4.0 0.6 36.4 9.729.9 273 287 7 35.4 20.0 40.0 4.0 0.6 34.2 10.0 34.8 280 313

Extruded pieces surprisingly incorporated the insoluble fiber withoutcompromising the texture or flavor of the pieces. Extruded piecesincluding relatively high amounts of fiber could be used in various foodproducts to increase protein and/or fiber content while providing anenjoyable eating experience.

Example 3

Extruded pieces having almond inclusions were produced. Formulationsincluding soy protein isolate (SPI), flour (F), inclusions (I), sugar(S), oil (O), water (W), and flavor (R) according to Table 4 (SPI, F, I,S, and R are shown as % weight of dry ingredients and O and W are shownas % weight of protein matrix composition) were combined to form aprotein matrix composition, formed, and dried similarly to Example 1. Itis noted that the amount of oil includes the amount contributed by boththe almond inclusions and added oil.

TABLE 4 SME Die Die Sam- (Wh/ temp. press. ple SPI F S R I W O kg) (°F.) (PSI) 1 65.4 30.0 4.0 0.6 12.3 31.5 12.0 27.9 273 348 2 65.4 30.04.0 0.6 11.6 35.5 11.3 26.5 266 325 3 65.4 30.0 4.0 0.6 10.8 39.9 10.523.8 261 287

Extruded pieces had an acceptable texture and macroscopicallyidentifiable almond pieces.

Samples were prepared for polarized light microscopy using the samehydration procedure and equipment as for the light microscopy in Example1, except the microscope was equipped with polarizing filters and firstorder red plate, and a 10×objective with a 10× eyepiece. As shown inFIG. 5, polarized light microscopy showed relatively largeagglomerations of non-linearly oriented protein surrounded by proteinmatrix disruptive ingredient in a loosely packed structure similar toSample 16 in Example 1. In addition, nut inclusions and bran areidentifiable, as shown in FIG. 5.

Example 4

Additional extruded pieces were produced that included a powderedprotein ingredient comprising a combination of soy protein isolate andwhey protein using a protocol similar to Example 1. The extruded pieceshad an acceptable texture, but were slightly cripsier than theacceptable samples in Example 1. Extruded pieces comprising whey proteincan be used to produce food products where a crispier texture isdesired.

Additional samples were also produced using a protocol similar toExample 1 and included a protein matrix disruptive ingredient thatcomprised apple powder (10% by weight dry ingredients), cinnamon (1.5-2%by weight dry ingredients), or cocoa powder (1.5-2% by weight dryingredients). The extruded pieces were determined to have an acceptabletexture. The samples that included apple flakes had a light color and anapple flavor. The samples that included cocoa were brown in color. Oatflour and rice flour were also tested as protein matrix disruptiveingredients, and both produced acceptable extruded pieces.

Additional inclusions were also tested, including dried cranberrypieces, rolled oats, whole sweet corn, coconut, flax seed, and chiaseed. All of the tested inclusions resulted in extruded pieces withmacroscopically visible inclusions.

The implementations described above and other implementations are withinthe scope of the following claims. One skilled in the art willappreciate that the present disclosure can be practiced with embodimentsother than those disclosed. The disclosed embodiments are presented forpurposes of illustration and not limitation.

What is claimed is:
 1. A composition comprising extruded pieces, theextruded pieces comprising: a. protein in an amount of about 30% toabout 90% by weight, b. a protein matrix disruptive ingredient in anamount of from about 5% to about 50% by weight, c. oil in an amount offrom about 2% to about 20% by weight, d. water in an amount of fromabout 1.5% to about 8% by weight, and e. inclusions in an amount of from0% to about 50% by weight.
 2. The composition of claim 1, wherein theextruded pieces comprise a substantially non-linearly oriented proteinmatrix.
 3. The composition of claim 1, wherein the extruded pieces havea texture analysis measurement of from about 1000 g to about 7400 gforce.
 4. The composition of claim 1, wherein the oil is substantiallyuniformly distributed throughout the extruded pieces.
 5. The compositionof claim 1, wherein the extruded pieces have a density of from about 0.5g/cc to about 1.0 g/cc.
 6. The composition of claim 1, wherein theextruded pieces comprise inclusions substantially uniformly distributedthroughout the extruded pieces.
 7. The composition of claim 1, whereinthe extruded pieces comprise a rough and/or uneven surface.
 8. Thecomposition of claiml, wherein the protein comprises soy protein.
 9. Thecomposition of claim 1, wherein the protein comprises whey protein, beanprotein, pea protein, wheat protein, canola protein, or algae protein.10. The composition of claim 1, wherein the protein matrix disruptiveingredient comprises a flour or a syrup.
 11. The composition of claim 1,wherein the protein matrix disruptive ingredient comprises a starch, asugar, or a fiber.
 12. The composition of claim 1, wherein theinclusions comprise nuts, seeds, fruit, grains, or coconut.
 13. Thecomposition of claim 1, wherein the extruded pieces comprise asugar-based coating, a fat-based coating, or a protein-based coating.14. The composition of claim 1 wherein an extruded piece is adhered withone or more edible component to form a cluster.
 15. The composition ofclaim 14, wherein the one or more edible component is one or moreadditional extruded piece.
 16. A food product comprising the compositionof claim 1 and food product pieces.
 17. A composition comprisingparticulates derived from extruded pieces, the extruded piecescomprising: a. protein in an amount of about 30% to about 90% by weight,b. a protein matrix disruptive ingredient in an amount of from about 5%to about 50% by weight, c. oil in an amount of from about 2% to about20% by weight, d. water in an amount of from about 1.5% to about 8% byweight, and e. inclusions in an amount of from 0% to about 50% byweight.
 18. The composition of claim 17, wherein the particulates arecoated on a food product.
 19. The composition of claim 17, wherein theparticulates are formed into a food product.
 20. A food product or kitcomprising the composition of claim 1 as a first food component, thefood product or kit further comprising a second food component.
 21. Amethod of making a protein product, comprising: processing, underextrusion conditions, a powdered protein ingredient comprising at least45% protein by weight of the powdered protein ingredient and a proteinmatrix disruptive ingredient combined with water and an oil to form aprotein matrix composition having a protein content of from about 10% toabout 65% by weight, a moisture content of from about 25% to about 55%by weight and an oil content of from about 1% to about 15% by weight,and forming the protein matrix composition into pieces to form theprotein product.
 22. The method of claim 21, wherein the extrusionconditions comprise a specific mechanical energy (SME) of from about 8Wh/kg to about 100 Wh/kg, a die pressure of from about 150 PSI to about1000 PSI, and/or a die temperature of from about 200° F. to about 350°F.
 23. The method of claim 21, wherein the powdered protein ingredientcomprises at least a portion of the protein matrix disruptiveingredient.
 24. The method of claim 21, wherein the protein matrixdisruptive ingredient comprises a flour or a syrup.
 25. The method ofclaim 21, wherein the protein matrix disruptive ingredient comprises astarch, a sugar, or a fiber.
 26. The method of claim 21, wherein thepieces comprise a substantially non-linearly oriented protein matrix.27. The method of claim 21, further comprising drying the protein matrixcomposition pieces to a moisture content of from about 1.5% to about 8%by weight to form extruded pieces.
 28. The method of claim 27, whereinthe extruded pieces have a texture analysis measurement of from about1000 g to about 7400 g force.
 29. The method of claim 27, wherein theextruded pieces have a density of from about 0.5 g/cc to about 1.0 g/cc.30. The method of claim 27, further comprising applying a sugar-based orprotein-based coating to the extruded pieces to form coated pieces anddrying the coated pieces.
 31. The method of claim 27, further comprisingapplying a fat-based coating to the extruded pieces to form coatedpieces and cooling the coated pieces.
 32. The method of claim 27,further comprising comminuting the extruded pieces to form particulates.33. The method of claim 32, further comprising producing a food productcomprising the particulates.
 34. The method of claim 32, furthercomprising coating a food product with the particulates.
 35. The methodof claim 21, wherein the oil is substantially uniformly distributedthroughout the pieces.
 36. The method of claim 21, further comprisingprocessing inclusions with the powdered protein ingredient, proteinmatrix disruptive ingredient, water, and oil.
 37. The method of claim36, wherein the inclusions comprise nuts, seeds, fruit, grains, orcoconut.